Transcript
APPLICARE TARGA CARATTERISTICHE
INSTRUCTION HANDBOOK
LABO XPL P
LABO XPL P
We wish to thank you for the preference granted to us by purchasing one of Carpigiani machines. To the best guarantee, since 1993 Carpigiani has submitted its own Quality System to the certification according to the international Standard ISO 9001, nowadays its production has got UNI-EN-ISO 9001:2008 Certified Quality System.
Moreover, Carpigiani machines comply with following European Directives: - “Machinery” Directive 2006/42/EC, - “Low Voltage” Directive 2006/95/EC, - “EMC” Directive 2004/108/EC, - “PED” Directive 97/23/EC, - Regulation 2004/1935/EC relating to “Materials and articles in contact with foodstuffs”
CARPIGIANI Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy Tel. +39 051 6505111 - Fax +39 051 732178 This manual contains a TRANSLATION OF THE ORIGINAL INSTRUCTIONS and may not be reproduced, transmitted, transcribed, filed in a data retrieval system or translated into other languages, without the prior written permission of CARPIGIANI. The purchaser has the wright to reprint it for his own office use. CARPIGIANI policy pursues a steady reasearch and development, thus it reserves the right to make changes and revisions whenever deemed necessary and without being bound to previous statements to the purchaser.
Issue: 02
Date: 2015/01
Changes: 3.3.1/4.2
Issued by: AM
Checked by: AM
Approved by: RL
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GENERAL INDEX FOREWORD........................................................................................................................ 5 INSTRUCTION HANDBOOK.................................................................................. 5 PURPOSE .............................................................................................................. 5 HANDBOOK STRUCTURE..................................................................................... 5 ADDITIONAL DOCUMENTATION........................................................................ 5 CONVENTIONAL SYMBOLS................................................................................. 6 SAFETY .............................................................................................................. 7 QUALIFICATION OF THE STAFF.......................................................................... 7 WARNING 7
SEC. 1 GENERAL INFORMATION
1.1
SEC. 2 INSTALLATION
1.2
1.3 1.4 1.5 1.6 1.7
GENERAL INFORMATION.................................................................................. 9 1.1.1 MANUFACTURER'S IDENTIFICATION DATA.......................................... 9 1.1.2 INFORMATION ABOUT SERVICE.............................................................. 9 1.1.3 INFORMATION TO THE USER................................................................... 9 INFORMATION ABOUT MACHINE................................................................... 9 1.2.1 GENERAL DATA............................................................................................ 9 1.2.2 TECHNICAL FEATURES............................................................................ 10 1.3.3 LOCATION OF MACHINE GROUPS..........................................................11 INTEDED USE........................................................................................................11 NOISE.......................................................................................................................11 STORING A MACHINE.........................................................................................11 DISPOSAL OF PACKING STUFFS......................................................................11 WEEE (Waste Electrical and Electronic Equipment)......................................... 12
2.1 ROOM NECESSARY TO THE MACHINE USE............................................... 13 2.2 WATER SUPPLY CONNECTION........................................................................ 13 2.3 MACHINES WITH AIRCOOLED CONDENSER............................................. 13 2.4 MACHINES WITH WATERCOOLED CONDENSER..................................... 14 2.4.1 WATER VALVE ADJUSTMENT................................................................. 14 2.5 ELECTRIC CONNECTION................................................................................. 14 2.5.1 REPLACING THE POWER CABLE........................................................... 14 2.6 LOCATION............................................................................................................. 15 2.7 REFILLING............................................................................................................ 15 2.8 MACHINE TESTING............................................................................................ 15
SEC. 3 DIRECTION FOR USE
3.1 MACHINE SAFETY WARNINGS....................................................................... 17 3.2 MACHINE CONFIGURATION........................................................................... 17 3.3 CONTROLS............................................................................................................ 18 3.3.1 ELECTRONIC CONTROL KEYBOARD................................................... 18 3.4 ICE CREAM PRODUCTION (PROCESSING)................................................. 19 3.4.1 ICE CREAM EXTRACTION....................................................................... 20 3.4.2 USE OF ICE CREAM DISPENSING HANDLE......................................... 20 3.4.3 FRONT LID CAM LOCKER....................................................................... 20 3.5 USER PROGRAMMING...................................................................................... 21
SEC. 4 SAFETY DEVICES
4.1 4.2
FRONT LID MICROSWITCH............................................................................. 23 MACHINE SAFETY DEVICES........................................................................... 23 -3-
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SEC. 5 CLEANOUT DISASSEMBLING AND REASSEMBLING OF PARTS IN CONTACT WITH THE PRODUCT
5.1 GENERAL DESCRIPTION.................................................................................. 25 5.2 WASHING CONDITIONS.................................................................................... 25 5.3 SUGGESTIONS ..................................................................................................... 25 5.4 HOW TO USE XSAN DETERGENT/SANITIZER............................................ 26 5.5 OUTSIDE CLEANOUT......................................................................................... 26 5.6 PRELIMINARY CLEANOUT.............................................................................. 26 5.7 BEATER DISASSEMBLY..................................................................................... 26 5.7.1 SLIDING SHOES DISASSEMBLY............................................................. 27 5.7.2 STUFFING BOX........................................................................................... 27 5.8 FRONT LID DISASSEMBLY............................................................................... 28 5.8.1 ICE CREAM DOOR DISASSEMBLY........................................................ 28 5.8.2 HOPPER COVER DISASSEMBLY............................................................. 28 5.8.3 PRODUCT CHUTE REMOVAL.................................................................. 28 5.9 SANITIZATION..................................................................................................... 29 5.10 HYGIENE................................................................................................................ 29
SEC. 6 MAINTENANCE
6.1 SERVICING TYPOLOGY.................................................................................... 31 6.2 WATERCOOLING................................................................................................. 32 6.3 AIRCOOLING........................................................................................................ 32 6.4 ORDERING SPARE PARTS................................................................................. 32 6.5 ACCESSORIES KIT.............................................................................................. 32
SEC. 7 TROUBLESHOOT GUIDE.....................................................................35
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FOREWORD INSTRUCTION HANDBOOK
Editing this handbook, it was taken into due account European Community directions on safety standards as well as on free circulation of industrial products within E.C.
PURPOSE
This handbook was conceived taking machine users' needs into due account. Topics relevant to a correct use of the machine have been analyzed in order to keep unchanged in the long run quality features charachterizing CARPIGIANI machines all over the world. A significant part of this handbook refers to the conditions necessary to the machine use and to the necessary procedure during cleanout as well as routine and special maintenance. Nevertheless, this handbook cannot meet all demands in details. In case of doubts or missing information, please apply to: CARPIGIANI
Via Emilia, 45 - 40011 Anzola dell'Emilia (Bologna) - Italy Tel. +39 051 6505111 - Fax +39 051 732178
HANDBOOK STRUCTURE
This handbook is divided in sections, chapters and subchapters in order to be consulted more easily. Section A section is the part of the handbook identifying a specific topic related to a machine part. Chapter A chapter is that part of a section describing an assembly or concept relevant to a machine part. Subchapter It is that part of a chapter detailing the specific component of a machine part. It is necessary that each person involved in the machine operation reads and clearly understands those parts of the handbook of his/her own concern, and particularly: The Operator must read the chapters concerning the machine star-up and the operation of machine components. A skilled technician involved in the installation, maintenance, repair, etc., of the machine must read all parts of this handbook.
ADDITIONAL DOCUMENTATION
Along with an instruction manual, each machine is supplied also with additional documentation: Part list: A list of spare parts which is delivered together with the machine for its maintenance. Wiring diagram: A diagram of wiring connections is placed in the machine.
Before using the machine read carefully the instruction handbook. Pay attention to the safety instructions.
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CONVENTIONAL SYMBOLS
CAUTION: ELECTRIC SHOCK DANGER The staff involved is warned that the non-observance of safety rules in carrying out the operation described may cause an electric shock. CAUTION DANGER FROM HIGH TEMPERATURES This warns the staff involved that failure to abide by safety rules in carrying out the operation described involves the risk of burns and scalds. CAUTION CRUSHING HAZARD This warns the staff involved that failure to abide by safety rules in carrying out the operation described involves the risk of suffering crushed fingers or hands. CAUTION: GENERAL HAZARD The staff involved is warned that the operation described may cause injury if not performed following safety rules. NOTE It points out significant information for the staff involved. WARNINGS This warns the personnel involved that the non-observance of warning may cause loss of data and damage to the machine, or cause risks for noncompliance with any applicable law/regulations. PERSONAL PROTECTIONS This symbol on the side means that the operator must use personal protection against an implicit risk of accident. EQUIPOTENTIAL CONNECTION For connecting all appliances with this type of connection. Warning: do not connect to ground. SYMBOLOGY QUALIFICATION OF THE STAFF The staff allowed to operate the machine can be differentiated by the level of preparation and responsibility in: MACHINE OPERATOR Unqualified personnel, without any specific technical abilities, capable of carrying out simple jobs, such as: operating the machine using the commands available on the keypad, the loading and unloading of products used during production, the loading of any consumable materials, basic maintenance operations, (cleaning, simple blockages, inspections of the instrumentation, etc.). QUALIFIED ENGINEER He/she is a skilled engineer for the installation and operation of the machine under normal conditions; he/she is able to carry out interventions on mechanical parts and all adjustments, as well as maintenance and repairs. He/she is qualified for interventions on electrical and refrigeration components.
CARPIGIANI ENGINEER He/she is a skilled engineer assigned by the manufacturer to interventions for complex jobs under particular conditions or in accordance with agreements made with the machine's owner. LABO XPL P_EN - 2015/01 - Ed. 02
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SAFETY When using industrial equipment and plants, one must be aware of the fact that drive mechanisms (rotary motion), high voltage components, as well as parts subject to high temperatures may cause serious damage to persons and things. Who is in charge of plant safety must be on the look-out that: • an incorrect use or handling shall be avoided; • safety devices must neither be removed nor tampered with; • the machine shall be regularly serviced; • only original spare parts are to be used especially as far as those components with safety functions are concerned (ex.: protection microswitches, thermostats); • suitable personal protective equipment is worn; • high care must be payed during hot product cycling. To achieve the above, the following is necessary: • at the working place an instruction manual relevant to the machine should be available; • tuch documentation must be carefully read and requirements must conse quently be met; • only adequately skilled personnel should be assigned to electrical equipment; IMPORTANT! One must be on the look-out that the staff does not carry out any operation outside its own sphere of knowledge and responsibility (refer to “Symbology qualification of the staff”).. NOTE: According to the standard at present in force, a SKILLED ENGINEER is who, thanks to: - training, experience and education, - knowledge of rules, prescriptions and interventions on accident prevention, - knowledge of machine operating conditions, is able to realize and avoid any danger and has also been allowed by the person in charge of plant safety to carry out all kinds of interventions.
WARNING When installing the machine, insert a differential magnetothermal protection switch on all poles of the line, adequately sized to the absorption power shown on machine data plate and with contact opening of 3 mm at least. • Never put your hand into the machine, alike during production and cleaning operations. Before carrying out any maintenance operation, make sure that the machine is in “STOP” position and main switch has been cut out. • It is forbidden to wash the machine by means of a bolt of water under pressure. • It is forbidden to remove panels in order to reach the machine inside before having disconnected the machine. • CARPIGIANI is not responsible for any accident that might happen during operation, cleaning and/or servicing of its units, if this warning has not been fully complied with.
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1.
GENERAL INFORMATION
1.1 GENERAL INFORMATION 1.1.1 Manufacturer's identification data
The machine has a data plate carrying manufacturer data, machine type and serial number, assigned when it is manufactured. Copy of machine data plate to be found on first page of this handbook. A
B
F
G Legend:
Matr.
Cod.
V A Gas kg
C
100089654588-4
ANZOLA EMILIA - BOLOGNA - ITALY
D
E
Hz
kW
A= Serial number B= Machine type C= Voltage D= Main-switch amperometric value E= Gas type and weight F= Machine code G= Condensation H= Frequency I= Power input
I
H
1.1.2 Information about service
All operations of routine maintenance are here described in section "Maintenance"; any additional operation requiring technical intervention on the machine must be cleared with the manufacturer, who will also examine the possibility of a factory technician field intervention.
1.1.3 Information to the user The manufacturer of the machine is at user's disposal for any explanation and information about the machine operation.
In case of need, please call the local distributor, or the manufacturer, if no distributor is avail-
able. Manufacturer's service department is available for any information about operation, and requests of spare parts and service.
1.2 INFORMATION ABOUT THE MACHINE 1.2.1 GENERAL DATA
LABO XPL P are batch freezers for the production of ice cream.
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LABO XPL P CARPIGIANI recommends to always use high quality mix for ice cream production in order to satisfy your customers, even the hardest-to-please ones. Any saving made to the prejudice of quality will surely turn into a loss much bigger than the saving itself. Bearing in mind the above statements, please take heed of the following suggestions: • Make your mixes yourselves from high quality natural ingredients or buy them from reliable companies. • Follow closely instructions given by your mix supplier for the preparation of the mixes. • Do not alter your mix supplier's recipies, by adding, for instance, water or sugar. • Taste ice cream before serving it and start selling it only if entirely satisfactory. • Make sure your staff always keeps the machine clean. Have your machine serviced always by companies authorized by CARPIGIANI.
1.2.2 Technical features Production output
Mix q.ty per batch
kg
Min. kg
Max. kg
kg
Volt
Hz
Ph
kW
Labo 20 30 XPL P 20/30 28/40
3
5
4
400
50
3
4
Water/Air*
52
Labo 30 45 XPL P 30/45 42/60
5
7,5
6,5
400
50
3
5,2
Water/Air*
52
Labo 40 60 XPL P 40/60 56/84
7
10,5
9
400
50
3
6
Water/Air*
52
MODEL
litres
Slush
electric spec.
Rated Power
Dimensions cm
Net weight
Width Depth Height
kg
Condenser 65 W 93 A 65 W 93 A 65 W 93 A
140
230
140
270
140
370
The quantity per cycle and hourly production change according to the mixes used. The values "Max" refer to the Italian classic easy-to-work ice-cream. * The air-cooled condenser is available with an extra charge. The following characteristics are purely indicative, Carpigiani reserves the right to make all the changes whenever necessary and without being bound to previous statements to the purchaser.
Fig. 1
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1.2.3 Location of machine groups 1
4 5
2
Caption: 1 2 3 4
Control panel Cylinder front lid Shelf for drip tray Drip drawer
3
Fig. 2
1.3
INTENDED USE
The LABO XPe must only be used for the production of ice cream, with the respect of what indicated in 1.2.1 "General information", within the limits indicated here under. Voltage: Min air temperature : Max air temperature: Min water temperature: Max water temperature: Min. water pressure: Max water pressure: Max relative humidity :
±10% 10°C 43°C 10°C 30°C 0,1 MPa (1 bar) 0,8 MPa (8 bar) 85%
This machine has been designed for its use in rooms not subject to explosion-proof laws; its use is thus bound to complying rooms and normal atmosphere.
1.4 NOISE The steady acoustic pressure level weighed A in a working place alike by watercooled and by aircooled machines is less than 70 dB(A).
1.5
STORING A MACHINE
The machine must be stored in a dry and dump-free place. Before storing the machine, wrap it in a cloth in order to protect it against dust and else.
1.6
DISPOSAL OF PACKING STUFFS
When opening the packing crate, separate packing stuffs per type and get rid of them according to laws in force in machine installation country.
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1.7
WEEE (Waste Electrical and Electronic Equipment)
In conformity with the European Directives 2006/66/EC, on batteries and accumulators and waste batteries and accumulators, and 2002/96/EC, also known as WEEE, the presence of the symbol on the side of the product or packaging means that the product must not be disposed of with normal urban waste. Instead, it is the user’s responsibility to dispose of this product by returning it to a collection point designated for the recycling of electrical and electronic equipment waste. Separate collection of this waste helps to optimize the recovery and recycling of any reclaimable materials and also reduces the impact on human health and the environment. For more information concerning the correct disposal of this product, please contact your local authority or the retailer where this product was purchased.
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2. INSTALLATION 2.1 ROOM NECESSARY TO THE MACHINE USE The machine must be installed in such a way that air can freely circulate all around. Rooms for the approach to the machine must be left free in order to enable the operator to act without constraint and also to immediately leave working area, if need be. The minimum approach room to working area should be at least 150 cm in consideration of space taken by opened doors. ATTENTION Machines with air-cooled condenser must have 20 cm. of free space along the sides in order to allow free air circulation around the condenser. NOTE An insufficient air circulation affects operation and output capacity of the machine.
Air 20 cm
Air 20 cm
150 cm
Fig. 3
2.2
WATER SUPPLY CONNECTION
The machine must be connected to running water which pressure must not be higher than 0,8 MPa (8 bars). By aircooled machines, water connection for drinking water (for machine wash) is placed under the machine. By watercooled machines water connections (for machine wash and gas cooling) are placed on upper panel.
2.3 MACHINE WITH AIRCOOLED CONDENSER Machines with air-cooled condenser must have 20 cm. of free space along the sides in order to allow free air circulation around the condenser. NOTE An insufficient air circulation affects operation and output capacity of the machine.
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2.4
MACHINES WITH WATERCOOLED CONDENSER
To make the machine run, a watercooled machine must be connected to running water supply, or to a cooling tower. Water must have a pressure of 0.1 MPa and 0.8 MPa (1-8 bar) at least, and a delivery at least equal to the estimated hourly consumption. Connect inlet pipe marked by plate "Water Inlet" to water supply installing a shut-off valve, and outlet pipe marked by plate "Water Outlet" to a drain pipe, installing a shut-off valve.
2.4.1 Water valve adjustment IMPORTANT If water valve needs be reset, this operation will have to be carried out by skilled personnel, only. Valve adjustment must be carried out in such a way that no water flows when machine is off and lukewarm water flows when machine is on. NOTE: Water consumption increases if temperature of entering water is above 20°C.
ATTENTION: Do not leave the machine in a room with temperature below 0°C without first draining water from the condenser.
2.5 ELECTRIC CONNECTION Before connecting the machine to the mains, check that machine voltage indicated in data plate corresponds with the mains. Insert a differential magnetothermal protection switch adequately sized to absorption capacity required and with contact opening of 3 mm at least. The machines are delivered with a 5 wire cable: blue wire must be connected to the neutral lead. IMPORTANT Yellow/green ground wire must be connected to an adeguate ground plate.
2.5.1 Replacing the power cable
Should the machine main cable be damaged, it must be replaced immediately through one with similar features. Replacement shall be carried out by skilled technicians, only. IMPORTANT Direction of rotation Beater rotation is anticlockwise Reversal of rotation Should direction of rotation be wrong, reverse it by exchanging two of the three phases which start at the differential magnetothermal protection switch.
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2.6 LOCATION The machine is provided with castors for an easy positioning; a mechanical block system, once engaged, prevents machine from moving and keeps it standstill.
Fig. 4
2.7 REFILLING Motor installed in the machine is of the type with lubrication for life; no action of checking/replacing or topping up is necessary. Gas filling necessary to the freezing system is carried out at CARPIGIANI works during machine postproduction testing. If a gas addition happens to be made, this must be carried out by skilled technicians, only, who can also find out trouble origin.
2.8 MACHINE TESTING A postproduction test of the machine is carried out at CARPIGIANI premises; Operation and output functionality of the machine are thoroughly tested. Machine test at end user's must be carried out by skilled technicians or by one of CARPIGIANI engineers. After the machine positioning and correct connections, also carry out all operations necessary to functional check and test of the machine.
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3.
DIRECTIONS FOR USE
3.1
MACHINE SAFETY WARNINGS
When using industrial equipment and plants, one must be aware of the fact that drive mechanisms (rotary motion), high voltage components, as well as parts subject to high temperatures may cause serious damages to persons and things. Who is in charge of plant safety must be on the look-out that: an uncorrect use or handling is avoided; safety devices must neither be removed nor tampered; only original spare parts are to be used especially as far as those components with safety functions are concerned (ex.: protection microswitches, thermostats); suitable personal protective equipment is worn. To achieve the above, the following is necessary: At working place an instruction manual relevant to the machine should be available. Such documentation must be carefully read and regulations must consequently be followed. Only adequately skilled personnel will have to be assigned to electrical equipment.
3.2 MACHINE CONFIGURATION The machine consists of motor drive for beater assembly drive, a cooling system with water- or aircooled condenser. Ice cream is made by pouring mix into the barrel and starting the automatic production cycle which ends when right consistency of ice cream as set by CARPIGIANI is reached. To this purpose, minum and maximum quantities of mix per batch must be followed, as shown in table Sec. 1.2.2. When cycle is over, ice cream is ready for being taken out from ice cream door and poured directly in ice cream cups and containers.
Ice cream mix
Ice cream (end product)
Fig. 5
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3.3 CONTROLS This machine is provided with an electronic control keyboard; every key relates to a machine function. For a correct use of the keys, press on the symbol or in the middle of the key; every key has a LED (light emitting diode) which lights up when relevant function is inserted.
3.3.1 Electronic control keyboard Labo
20 30 XPL P
Labo
STOP In this function, the machine is idle and the relevant red LED is on. The display shows STOP. The backlighting on the display will switch off after 3 minutes; press any key to switch it on again.
Labo
WATER DISPENSER Pressing the water dispenser key at any time activates the dispensation of water by the wand positioned on the front panel. Press the water dispenser key again or press the STOP key or wait 3’ to stop the supply of water.
30 45 XPL P
40 60 XPL P
PRODUCTION Pressing the production key will show the cycles on the display: - GELATO - SLUSH FRUTI (cremolata) - GELATO FRUIT (Sorbet), Use the Increment and Decrement keys to move the asterisk to the required cycle.
* GELATO GELATO FRUIT
Press Production again to start the cycle or wait 5’’. GELATO/ GELATO FRUIT (SORBETTO) CYCLE The product is chilled in the cylinder for the time set on the display or to the set consistency (Hot). According to the chosen cycle, Gelato or Gelato Fruit, a suitable Set HOT Consistency is automatically set. For the Ice cream cycle the following is displayed:
SET 100 HOT 005
While for Fruit Ice cream cycle:
SET 090 HOT 005
SET is the consistency to be reached (it can be modified by pressing Increase/ Decrease keys) HOT is the current consistency If the Production key is pressed for 3”, the display will show the timers:
060 20:00 HOT 033
The timer, after the threshold is displayed in the upper left area, the timeout prd in the upper right area and real HOT at the bottom.
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LABO XPL P After 60” the buzzer rings intermittently. After 20” the buzzer turns off. After the 15’-timer reaches zero (HOT
